Flow reducing overlying panel and method

ABSTRACT

A panel includes a sheet of material and an array of spaced projections on the sheet. The projections are cut and folded from the sheet, cast or molded. The projections create turbulence in drainage across the sheet, increasing drag and reducing flow velocity. The panel is mounted in a roof valley, along roof eaves above the rain gutters or anywhere that excess drainage flow velocity can create a problem. The panel is also an improved snow and ice guard for a roof.

[0001] This application claims the benefit under 35 U.S.C. section 119(e) of the U.S. provisional patent application No. 60/475,851 filed Jun. 4, 2003.

TECHNICAL FIELD

[0002] The present invention relates to drainage systems and more particularly to a panel with an array of surface projections that reduce flow velocity in drainage water.

BACKGROUND ART

[0003] Water from a relatively large roof area drains into and down the valley at the juncture of two intersecting roof sections. Generally smooth flashing is used in roof valleys. The high water volume combined with the smooth flashing creates a high velocity stream of water that shoots over the rain gutter at the bottom of the valley. Gutter hoods, screens and covers are often provided to prevent debris from entering the rain gutter while allowing water drainage into the gutter. The high velocity stream from the roof valley also renders these gutter hoods, screens and covers ineffective. Smooth roofing materials, such as metal panels and slate tile, during heavy rain conditions, can also experience high velocity flows that overshoot rain gutters.

[0004] Prior known devices that have addressed the high velocity flow from roof valleys include splash guards and diverters. The splash guards are generally mounted on the outside of rain gutter, opposite the roof valley. Such splash guards are incompatible with gutter hoods, screens and covers and cause accumulation of debris in the rain gutter at the bottom of the roof valley. U.S. Pat. No. 1,986,383 to Usinger and U.S. Pat. No. 2,899,916 to Ertman disclose such splash guards. The diverters generally mount above the bottom of the roof valley and redirect water outward from the roof valley so that runoff water from the roof valley enters the gutter system along a length of rain gutter. Such diverters often collect debris and require frequent cleaning. U.S. Pat. No. 5,333,417 to Demartini, U.S. Pat. Nos. 5,333,419 and 5,675,939 to Hickner, and U.S. Pat. No. 6,412,229 to Kuhns disclose such diverters.

[0005] Snow guards are often provided for roofs with slick surfaces, such as metal or tile, to prevent injury or damage from high speed snow slides of snow accumulated on the roof. The two most prevalent types of snow guard are the fence and the field array. Generally the fence type snow guard is a fence of vertically spaced horizontal rods mounted on the roof above the rain gutters. Field array snow guards are arrays of widely spaced upright projections on the roof that split up and slow the slide of snow off the roof.

[0006] U.S. Pat. No. 6,141,917 to Mueller discloses an array of smooth projections that act as a snow guard integrated into the waterproof metal roofing panel. The projections are shaped to act similar to the diverters discussed above and the disclosed shapes do not create turbulence in drainage water.

DISCLOSURE OF THE INVENTION

[0007] An overlying panel for a structure includes a panel body of sheet material with a top surface and an array of projections formed on the top surface. The panel is mounted above the rain gutter in a roof valley or along the eaves. The shape, sizing and arrangement of the projections is selected to induce turbulence in drainage water flowing over the panel to increase drag and thereby reduce flow velocity. Several types of projections include an edge that induces boundary layer separation. The projections are arranged in a staggered array or an interlaced array.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Details of this invention are described in connection with the accompanying drawings that bear similar reference numerals in which:

[0009]FIG. 1 is a perspective view of a roof with flow reducing overlying panels embodying features of the present invention.

[0010]FIG. 2 is a perspective view of a flow reducing overlying panel embodying features of the present invention.

[0011]FIG. 3 is a side view of a projection of the panel of FIG. 2.

[0012]FIG. 4 is a front view of the projection of FIG. 3.

[0013]FIG. 5 is a perspective view of another configuration of the panel of FIG. 2.

[0014]FIG. 6 is a perspective view of another projection of the panel of FIG. 2.

[0015]FIG. 7 is a perspective view of another projection of the panel of FIG. 2.

[0016]FIG. 8 is a perspective view of the panel of FIG. 2 with another projection.

[0017]FIG. 9 is a perspective view of the panel of FIG. 2 with another projection.

[0018]FIG. 10 is a perspective view of the panel of FIG. 2 with another projection.

[0019]FIG. 11 is a perspective view of the panel of FIG. 2 with another projection.

[0020]FIG. 12 is a perspective view of another panel embodying features of the present invention.

[0021]FIG. 13 is a perspective view of the panel of FIG. 12 with another projection.

[0022]FIG. 14 is a perspective view of another panel embodying features of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0023]FIG. 1 shows flow reducing overlying panels 11 embodying features of the present invention mounted on a roof 8. The panels 11 shown are mounted in a roof valley 9, and on the eave 10, adjacent the rain gutter 12.

[0024] Describing the specific embodiments herein chosen for illustrating the invention, certain terminology is used which will be recognized as being employed for convenience and having no limiting significance. For example, the terms “up”, “down”, “vertical”, and “horizontal” refer to the illustrated embodiment relative to the primary flow direction of drainage water on the surface. Further, all of the terminology above-defined includes derivatives of the word specifically mentioned and words of similar import.

[0025] Referring now to FIGS. 2, 3 and 4, the panel 11 includes a substantially planar panel body 13 of sheet material having a top surface 14 with an array 15 of projections 16 thereon. The panel body 13 has a upper end 17 and a spaced lower end 18, and a primary flow direction for a liquid substantially from the upper end 17 to the lower end 18. The panel body 13 shown in FIG. 2 is a relatively horizontally narrow, vertically elongated strip for attachment to a roof valley and is sheet metal. Other materials may be used such as synthetic materials or plastics.

[0026] The array 15 shown is a regular pattern including a plurality of spaced horizontal rows 19 of projections 16, with alternating rows 19 of two and three projections 16 per row 19. Adjacent projections 17 have a space 18 therebetween. The array 15 can have a regular or an irregular pattern. The projections 16 of each row 19 are staggered or offset relative to the projections 16 in adjacent rows 19. The projections 16 in the array 15 are arranged such that there are no clear or unobstructed flow paths in the primary flow direction. In the array 15 shown, the projections 16 in a row 19 are aligned with the spaces 18 of adjacent rows 19 and the width of the spaces 18 is less than the width, measured perpendicular to the primary flow direction, of the projections 16. The spacing between the rows is selected such that water flow from a projection 16 does not reaccelerate significantly before encountering another projection 16, and is dependent on the slope of the roof.

[0027] The projections 16 shown have a generally triangular shape when viewed from the side and are each formed by cutting the spaced sides 20 and the bottom end 21 of a rectangle 22 on the panel body 13. The rectangle 22 is folded along the top end 23 away from the panel body 13 at an acute angle, and creased intermediate the top end 23 and the bottom end 21, back towards the panel body 13, so that the bottom end 21 is planar with panel body 13. The projection 16 shown is creased near the middle of the rectangle 22 so that the shape is an isosceles triangle. An opening 24 is created in the panel body 13 from the bottom end 21 downwards to the panel body 13. Other shapes may be cut in the panel body 13 and folded, preferably along the top, away from the panel body 13. Preferably the shapes present an edge 25 that faces transverse to the primary flow direction, to create boundary layer separation and turbulence in the fluid flow.

[0028] The dimensions and spacing of the projections 16 are selected so that the array 15 induces turbulence, and thereby reduces flow velocity, in water flowing over the panel 11, while limiting the debris catching capacity. The width of the projections 16, measured in the plane of the panel body 13 perpendicular to the primary flow direction, can be in the range of about ½ to {fraction (3/4)} inches. The depth of the projections 16, measured perpendicular to the plane of the panel body 13, can be in the range of about ¼ to {fraction (3/8)} inches.

[0029] The shape of the projections 16 is selected to reduce flow velocity while limiting debris collection, providing relatively easy and low cost manufacture, and providing an aesthetically pleasing look by limiting display of the underside color of panel body 13. The sides 20 of the projections 16 shown have sharp edges. The sharp edges create boundary layer separation and turbulence in the fluid flow. The boundary layer separation and turbulence lead to drag, which reduces or limits the flow velocity. The opening 24 and the edge 25 of the projections 16 also provide improved snow and ice holding capabilities and the panel 11 is also an improved snow guard.

[0030]FIG. 5 shows a panel 11 embodying features of the present invention includes a panel body 13 of material with an array 15 of projections 16 thereon. The panel body 13 shown is a relatively vertically narrow, horizontally elongated strip for attachment to a roof section above a rain gutter. The panel 11 reduces flow velocity of water flowing into the rain gutter, preventing overshoot and, in gutter guard systems that depend on water surface tension to separate debris, assuring debris separation.

[0031]FIG. 6 shows a similar projection 16 for a panel 11 embodying features of the present invention. The projection 16 shown is creased nearer the bottom end 21 of the rectangle 22 than the top end 23 so that the shape is a scalene triangle.

[0032] Referring to FIG. 7, another projection 26 for a panel 11 embodying features of the present invention having a generally downward pointing chevron shape. The projection 26 has two opposed, angled tapering wedges 27. Each wedge 27 is formed from a triangle 28 in the panel body 13 with the inner sides 29 of the triangles 28 being adjacent and angled away from each other. The inner side 29 and bottom side 30 is cut, the triangle 28 is folded along the top side 32 away from the plane of the panel body 13, and the triangle 28 is creased between the bottom and top sides 30 and 31, so that the bottom side is in the plane of the panel body 13.

[0033]FIG. 8 shows a panel 11 embodying features of the present invention with another projection 33. The projections 33 have a generally dome shape and are arranged in alternating rows 19 of one or two projections 33. The projections 33 have a selected size and spacing to induce turbulence in water draining down the panel 11. The projections 33 can be pressed from a panel body 13 of sheet metal.

[0034] Referring to FIG. 9, a panel 11 embodying features of the present invention includes another projection 34. The projections 34 have a closed cylindrical shape and are arranged in alternating rows 19 of two or three projections 34. The projections 34 have a selected size and spacing to induce turbulence in water draining down the panel 11. The projections 34 can be cast into a panel body 13 of polymer or metal.

[0035]FIG. 10 shows a panel 11 embodying features of the present invention with another projection 35. The projections 35 are a generally annular or open cylinder shape and are arranged in alternating rows 19 of two or three projections 35. The projections 35 have a selected size and spacing to induce turbulence in water draining down the panel 11.

[0036] Referring to FIG. 11, a panel 11 embodying features of the present invention includes another projection 36. The projections 36 are chevron shaped and are arranged in alternating rows 19 of one or two projections 36. The projections 36 have a selected size and spacing to induce turbulence in water draining down the panel 11. The projections 33, 34, 35 and 36 are small enough, as described above for projection 16, to present an edge transverse the primary flow direction and thereby create boundary layer separation and turbulence.

[0037]FIG. 12 shows another panel 40 embodying features of the present invention having an array 41 of interlaced projections 35. Each projection 42 has an elongated tent shape with a triangular cross section. The array 41 includes two overlapping columns 43 with the spaced projections 42 of each column 43 angling downwardly toward the inside of the array 34. The projections 42 can be formed or cast into a panel body 13 of metal or plastic.

[0038] The panel 40 is shown in FIG. 13 with another projection 45. The projection 45 is a rectangle 46 with a top end 47, a bottom end 48 and spaced sides 49. The projections 45 can be formed cast in a panel body 13 of metal. The bottom end 48 and sides 49 are cut from the panel body 13 and the rectangle 46 is folded along the top end 47 to be substantially perpendicular to panel body 13.

[0039]FIG. 14 shows a projection 52 for another panel 51 embodying features of the present invention. The projection 52 extends across the panel body 13 and has two spaced, interlaced deep ridges 53. The deep ridges 53 are formed on opposite sides of the panel body 13 and are staggered vertically. The deep ridges 53 are each created from a trapezoid 54 that is cut along the inner side 55, folded away from the plane of the panel body 13 along the top and bottom ends 56 and 57, and creased between the top and bottom ends 56 and 57. A shallow ridge 58 connects from the intersection of the inner side 55 and the top end 56 of each deep ridge 53 to the opposite side of the panel body 13, forming a raised planar area 59 that extends between the deep ridges 53.

[0040] Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in details of structure may be made without departing from the spirit thereof. 

What is claimed is:
 1. An overlying panel for mounting on a structure, comprising: a panel body having an upper end, a lower end and a top surface extending between said upper end and said lower end, said body panel having a primary flow direction for a liquid substantially from said upper end to said lower end, and an array of projections on said top surface, said projections each having an edge transverse said primary flow direction, whereby each said edge creates turbulence in said liquid to increase drag and thereby reduce said velocity of said flow of said liquid, and each said projection grips ice and snow on said top surface.
 2. The panel as set forth in claim 1 wherein said array includes a plurality of vertically spaced horizontal rows of said projections with a space between adjacent said projections, said projections being staggered such that a said projection in a said row is aligned with said spaces between said projections in adjacent said rows.
 3. The panel as set forth in claim 1 wherein said array includes a plurality of vertical columns of interlaced projections.
 4. The panel as set forth in claim 1 wherein said projections are formed from said panel body.
 5. The panel as set forth in claim 4 wherein said projections are a each a shape cut into said panel body with said shape being folded away from said panel to form an opening in said panel.
 6. The panel as set forth in claim 5 wherein said shape is a rectangle with a top end, a bottom end and spaced sides, said rectangle being cut along said bottom end and said sides, and folded away from said panel body along said top end.
 7. The panel as set forth in claim 6 wherein said rectangle is creased between said top end and bottom end back toward said panel body so that said projection has a triangular shape side view.
 8. The panel as set forth in claim 5 wherein said shape is a pair of angled triangles that are folded into a chevron shaped projection.
 9. The panel as set forth in claim 4 wherein said panel body is sheet metal.
 10. The panel as set forth in claim 4 wherein said panel body is a plastic sheet.
 11. The panel as set forth in claim 1 wherein said projections have a dome shape.
 12. The panel as set forth in claim 1 wherein said projections have a cylindrical shape.
 13. The panel as set forth in claim 1 wherein said projections have an annular shape.
 14. The panel as set forth in claim 1 wherein said projections have a chevron shape.
 15. An overlying panel for mounting on a structure, comprising: a panel body of sheet metal for drainage of a liquid, said panel body having an upper end, a lower end and a top surface extending between said upper end and said lower end, said body panel having a primary flow direction for said liquid substantially from said upper end to said lower end, and an array of projections on said top surface, each projection being cut from a rectangular shape having a top end, a bottom end and spaced sides with said bottom end and said sides being cut in said panel body, said rectangle being folded along said top end away from said panel body, and said rectangle being creased between said top end and bottom end back toward said panel body so that said projection has a triangular shape side view, an opening in said panel body between said bottom end and said panel body, and a sharp edge transverse said flow, said array including a plurality of vertically spaced horizontal rows of said projections with a space between adjacent said projections, said projections being staggered such that a said projection in a said row is aligned with said spaces between said projections in adjacent said rows, whereby each said edge creates turbulence in said liquid to increase drag and thereby reduce said velocity of said flow of said liquid, and each said projection grips ice and snow on said top surface.
 16. A method of reducing flow velocity of water having a primary flow direction on a roof, comprising the steps of: providing a panel of material having a top surface, creating an array of spaced projections on said top surface, said projections each having an edge, and applying said panel to said roof with said edges transverse said primary flow direction, whereby each said edge creates turbulence in said liquid to increase drag and thereby reduce said velocity of said flow of said liquid, and each said projection grips ice and snow on said panel.
 17. The method as set forth in claim 16 wherein said step of applying includes applying said panel to a roof valley.
 18. The method as set forth in claim 16 wherein said step of applying includes applying said panel substantially horizontally as a strip above a rain gutter.
 19. The method as set forth in claim 16 wherein said projections are arranged in a plurality of spaced, staggered rows.
 20. The method as set forth in claim 16 wherein said projections are arranged in interlaced columns.
 21. The method as set forth in claim 16 wherein said panel is sheet metal, each said projection is a shape, and said step of creating includes, for each said projection, cutting a portion of said shape in said panel and leaving an uncut end, folding said shape away from said panel along said uncut end, and thereby creating an opening in panel.
 22. The method as set forth in claim 21 wherein said shape is a rectangle and said uncut end is a top end.
 23. The method as set forth in claim 16 wherein said step of creating includes casting said projections into said panel.
 24. A method of reducing flow velocity of water in a roof valley on a roof, said water having a primary flow direction down said valley, comprising the steps of: providing a panel of sheet metal having a top surface creating an array of spaced, staggered rows of spaced projections on said top surface, each said projection having a rectangular shape with a bottom end, a top end and spaced sides, said creating including cutting said bottom end and said spaced sides in said panel and folding said projection away from said panel along said top end, and thereby creating an opening in panel for each said projection, and applying said panel to said roof valley with said sides transverse said primary flow direction, whereby said projections generate turbulence in said water and thereby reduce said flow velocity.
 25. A method of reducing flow velocity of water having a primary flow direction on a roof, comprising the steps of: providing a panel of sheet metal having a top surface creating an array of spaced, staggered rows of spaced projections on said top surface, each said projection having a rectangular shape with a bottom end, a top end and spaced sides, said creating including cutting said bottom end and said spaced sides in said panel and folding said projection away from said panel along said top end, and thereby creating an opening in panel for each said projection, and applying said panel to said roof above a rain gutter with said sides transverse said primary flow direction, whereby said projections generate turbulence in said water and thereby reduce said flow velocity. 